1. Lighting Tool Box Machine Vision Lighting
Team Members:
B. Thompson
N. Sitarski
B. Harris
D. Chronicle
V. Gergov
Advisor:
J. W. Miller
University of Michigan-Dearborn

2. Introduction to Lighting Tool Box
Lighting Tool Box system function and purpose
Lighting Tool Box components
LED Light Controller
Incandescent Light Controller
Florescent Lamp Controller
Computer

3. Design Objectives
The goal is to design and implement three lighting systems that can be remotely controlled via the internet or locally in a stand alone configuration.

4. Implementation Choices
Linux/GNU Operating System
Stability
Cost
Scalability
Open Source
PC104 Embedded System
Size
Heat-load
No moving parts

5. Implementation Choices cont.
Custom hardware for lighting controllers
Off the shelf products are non-existent
Flexibility to make changes
Cost

6. High Level System Block Diagram
Incandescent
Server
(PC104)
Incandescent
Light System
Web Cam
LED
Ring
Light
Internet
Light System
Fluorescent
Fluorescent
Light System
Client

7. High Level Block Diagram Incandescent Lighting controller
120V AC
Power Supply
Light
GND
MOSFET
LPF
Driver
PWM
Local/Remote

8. Low Level Block Diagram Power Supply
Vin 120 V RMS
Vout 12 Volts to 18 Volts Unregulated
Rectifier Circuit has a PIV of 36 Volts Diodes Rated at 50 Volts
Maximum Current of Circuit is 20 Amps
Capacitor was Calculated with I=C*(dv/dt) , C = (20 (amps) * 8 (ms)) / 6 (V) = 27,000 uF
68,000 uF Electrolytic was the value closest to the calculated value

9. Low Level Block Diagram Signal Conditioner
Differential Amplifier measures voltage across lamp
Scales voltage to level compatible with computer input
Provides Isolation between lamp circuit and computer

10. Low Level Block Diagram MOSFET Driver
MOSFET operated in saturation region of curve
Provides efficient switching to lamp load
Low heat dissipation

11. High Level Block Diagram LED Light Controller
System Health
Power
Supply
12 VDC
5 VDC
PWM
Oscillator
Select
Logic
MOSFET
Driver
LED Light
Ring
Remote PWM
External
Sync

12. Schematic Diagram Power Supply

13. Schematic Diagram Select Logic

14. Over Voltage Alarm Circuit

15. PWM Oscillator 40 KHz

16. Commercially Available Ring Lights

17. Bright Field vs. Dark field
Bright Field - Light is aimed directly at an object, often creating distinct shadows. Effective for high degrees of contrast, but can creates specular reflections
Dark Field – Light is projected at an angle to the surface, causing any variations to deflect light up into the camera. Nothing is seen by the vision system if there are no aberrations on the surface.

18. High Level Block Diagram Fluorescent Lighting Controller
Circular
Fluorescent
Lamp
Server
(PC104)
Fluorescent
Controller

19. Fluorescent Lamp Intensity control circuit schematic

20. Project Changes
Lighting controllers will have the capability of being controlled in stand alone configuration.

21. Dave And Vladi’s Completed Tasks
Acquired all needed parts (PC104, I/O Board, 2.5” HDD, Flash, Web Cam, Enclosures, Misc.)
Assembled PC104 and Modules
Installed/Streamlined Debian GNU/Linux OS on PC104 (under 100 MB compared with ~1.2 GB min Windows install )
Custom Linux Kernel configured and compiled with i586 optimization, preemptive task scheduler, and low latency patches
Web Cam Installed and configured with our kernel
Web Site code completed in PHP, XHTML 1.0 Strict, and CSS 2.0 in accordance with W3C standards
Web Site daemon control module Coded
Web Cam Snapshot BASH Script Coded

22. Dave and Vladi’s Remaining Tasks
Digital I/O Card integration into our kernel
Digital I/O daemon control code
Testing of code with actual lighting systems
Achieve system boot time of ~ 3 sec
Miscellaneous enhancements of code and Operating System

23. Nick’s Completed Tasks
Power Supply design, test, and construction
MOSFET Driver Circuit design, test, and construction
Lamp Filter design, test and construction
Lamp Head design and construction
Heat sinks have been sized and installed on high temperature components
All components have been installed and tested in a commercially available electronics cabinet, unit is fully functional in local mode of operation

24. Nick’s Remaining Tasks
Implement computer interface circuit
Integrated test of finished product

25. Blaine’s Completed Tasks
Regulated Power Supply design, test, and construction
MOSFET Driver Circuit design, test, and construction
Strobe circuit design, test and construction
Remote/ Local select logic design, test, and construction
LED Ring Light Head design and construction
Heat sinks have been sized and installed on high temperature components
Computer interface circuit
All components have been installed and tested in a commercially available electronics cabinet, unit is fully functional in local mode of operation

26. Blaine’s Remaining Tasks
Integrated system test
Possible additional Ring Light configurations

27. Brandon’s Completed Tasks
Dimmable (from 1 to 100%) 32 watt fluorescent lamp dimmer circuit assembled on board
0-5VDC intensity control circuit
System test with 32 watt lamp

28. Brandon’s Remaining Tasks
Install components in cabinet
Construct shadow box for transmitted lighting applications
Research circuit modification requirements to operate a 40 watt lamp
Integrated system test

29. Timeline for Remaining Tasks
February
1-14
15-28
March 1-15
March
16-31
April
1-25
Implement computer interface hardware
Debug computer interface hardware
Develop PWM code
Integrated System Test
Refine and debug computer interface software
Prepare for demonstration
Give Demonstration
Complete Final Report

30. Any questions, comments, or suggestions?
Feedback
Any questions, comments, or suggestions?